DC electrical systems for chlorine refining and chlor-alkali production
G Corner is the world's most experienced and provider of specialist DC electrical busbar systems for the chlorine refining industry. With a track record stretching back to the 1970s, we have supported the industry through decades of technological change, from mercury electrolysis to modern bipolar electrolyser technologies.
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Introduction
Chlorine refining is a chemically complex, safety-critical process that places exceptionally demanding requirements on DC electrical system design and performance.
Continuous operation, highly corrosive environments, and the need for precise current distribution across large electrolyser stacks mean there is little margin for error. Systems that underperform or fail create serious safety risks and costly production losses. G Corner has been engineering solutions for these challenges since the 1970s, building a depth of knowledge unmatched by any other supplier in this sector.
We have delivered successful installations for chlor-alkali, sodium hydroxide, and chlorine dioxide – mainly all chlorine derivatives facilities across Europe, the Americas, Asia, and beyond, supporting customers through the industry's transition from mercury-cathode technology to cleaner, more efficient modern electrolyser designs.
Caustic soda and sodium hydroxide
Chlorine dioxide production
Liquid chlorine refining
Chlorine refining facilities expose electrical systems to aggressive chemical environments that accelerate material degradation, promote corrosion, and reduce the service life of poorly specified components. Conductor materials, insulation systems, and support structures must all be selected and engineered with this environment in mind. G Corner's extensive experience in chlorine refining means we understand exactly which materials, coatings, and design approaches are required to deliver long service life in these conditions. Our systems are engineered from the outset for the specific chemical exposure they will face, minimising maintenance requirements and protecting long-term reliability.
The chlorine industry has undergone significant technological change over recent decades, moving from mercury-cathode electrolysis through diaphragm technologies to modern monopolar and bipolar electrolyser designs. Each generation of technology places different demands on DC electrical systems in terms of current levels, voltage requirements, and physical configuration. G Corner played a leading role in supporting this transition for customers worldwide, developing and adapting our busbar system designs to meet the requirements of each new electrolyser generation. Customers undertaking technology upgrades benefit from our ability to design systems that integrate with new electrolyser platforms without requiring a complete overhaul of existing infrastructure.
Chlorine production is classified as a major hazard process in most regulatory frameworks. Electrical system failures that cause production interruptions, arcing, or uncontrolled current flow carry serious safety consequences alongside the commercial cost of downtime. G Corner designs systems with safety as a primary engineering parameter, ensuring correct insulation clearances, robust fault isolation capability, and components that perform predictably under all operating conditions. Our in-house high-voltage testing facility, operating at up to 100KV AC and 10KV DC, provides documented verification of dielectric performance before any system leaves our facility.
In chlorine electrolysis, uniform current distribution across the electrolyser stack is critical for consistent product quality, efficient energy use, and electrode longevity. Uneven distribution accelerates wear on individual cells, increases energy consumption, and can compromise product purity. G Corner's engineering team develops detailed current distribution models for every project, optimising busbar sizing and layout to ensure uniformity across the full stack. This is validated through millivolt drop testing in our facility before despatch, with commissioning verification on site confirming the system performs as modelled under live operating conditions.
What our customers say about us
"G Corner are a very professional and reliable supplier who have a demonstrated ability in handling design changes and additions yet still meeting project delivery requirements and I have no hesitation in recommending them to anyone for this type of work."
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